Intake Manifold Replacement - Lower

Removal Procedure






1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
2. Disconnect the battery negative cable from the battery. Refer to Battery Cable.
3. Remove the upper intake manifold from the lower intake manifold.
4. Remove the suction line from Air Conditioning from the A/C compressor. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
5. Remove the distributor from the lower intake manifold. Refer to Distributor Replacement.
6. Remove the MAP sensor from the lower intake manifold. Refer to MAP Sensor Replacement.
7. Remove the radiator hose from the thermostat. Refer to Radiator Hose Replacement in Cooling System.
8. Remove the thermostat housing from the lower intake manifold from the engine block. Refer to Thermostat Replacement in Cooling System.
9. Remove the heater hoses from the heater core. Refer to Heater Hoses Replacement (Inlet) and Heater Hoses Replacement (Outlet Hose) in Cooling System.
10. Remove the coolant bypass hose from the lower intake manifold and the water pump.
11. Remove the retaining bolts for the fuel rail. Refer to Fuel Rail Assembly Replacement.
12. Remove the fuel rail from the lower intake manifold. Refer to Fuel Rail Assembly Replacement.
13. Remove the lower intake manifold bolts from the engine head.
14. Remove the lower intake manifold from the cylinder head.
15. Remove the lower intake manifold gaskets and seals from the cylinder head.
16. Clean all sealing surfaces of oil and grease. Refer to Intake Manifold Clean and Inspect (Lower).


Installation Procedure






1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the engine block.
3. Apply bolt thread locking material to the lower intake manifold bolts.






Notice: Refer to Fastener Notice in Service Precautions.

4. Install the lower intake manifold bolts to the engine head.
^ Tighten the bolts in sequence to 30 Nm (22 ft. lbs.).
^ Re-tighten the bolts in sequence to 40 Nm (30 ft. lbs.).
5. Install the fuel rail to the lower intake manifold. Refer to Fuel Rail Assembly Replacement.
6. Install the fuel rail retaining bolts. Refer to Fuel Rail Assembly Replacement.
7. Install the coolant bypass hose to the water pump.
8. Install the heater hoses to the lower intake manifold. Refer to Heater Hoses Replacement (Inlet Hose) and Heater Hoses Replacement (Outlet Hose) in Cooling System.
9. Install the thermostat housing to the lower intake manifold from the engine block. Refer to Thermostat Replacement in Cooling System.






10. Install the MAP sensor to the lower intake manifold. Refer to MAP Sensor Replacement.
11. Install the radiator hose to the thermostat housing. Refer to Heater Hoses Replacement (Inlet Hose) or Heater Hoses Replacement (Outlet Hose) in Cooling System.
12. Install the distributor to the engine block. Refer to Distributor Replacement.
13. Install the suction hose to the A/C compressor. Refer to Heater Hoses Replacement (Inlet Hose) in Heating and Air Conditioning.
14. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Installation.
15. Install the discharge line to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
16. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
17. Connect the battery negative cable to the battery. Refer to Battery Cable.